MEC041

Production Engineering

MEC122
Manufacturing Technology For Health
Science

Bench Work and Fitting

Mohamed Soliman
Faculty of Engineering
Galala University
Definition
Fitting, is related to assembly of parts, after bringing the dimension or
shape to the required size or form

The fitting operations are generally done by using hand tools, after holding and
placing the workpiece on a work bench. The tools and related equipment used for
fitting processes can be classified as:

1. Work holding devices

2. Cutting tools
3. Measuring and marking tools
4. Tools for assembling and inspection

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1. Work Holding Devices
Work bench
1.1. Work Bench
The work bench is a strong, heavy and rigid
table made up of hard wood.

Work bench with

vice.

The Work benches are nearly 90 cm width and 76 to 84 cm height.

Bench vice, is the device used to hold the workpiece and it is rigidly clamped on the
top of the table

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1. Work Holding Devices
1.2 Bench Vice
It is the most widely used device for holding the workpiece in position during various operations which
are carried out in a fitting shop.
The gripping property of the jaw plates is increased by serrations provided with them.
In order to avoid the gripping marks on a finished surface of the workpiece, soft liners
may be used on the jaw surfaces. The size of the vice is usually specified by the width of
the jaws. The jaw size varies from 80 to 140 mm and the maximum opening ranges from
95 to 180 mm.

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1. Work Holding Devices
1.3. Hand Vice
For gripping small objects like screws, rivets,
keys, etc., a hand vice is used. To keep the jaws
separate, a leaf spring is provided nearby the
hinged end. The jaws can be opened and
closed by operating a wing nut and the screw.

1.4. V-block with Clamp

Cylindrical objects can be clamped for drilling
or similar operations by using a
V-block and a U-clamp

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2. Cutting Tools
2.1. Files
A file is a hardened piece of steel containing a high percentage of carbon or
tungsten.
Fine teeth are cut on the surface of the piece in slanting rows. The end called heal
has a pointed portion called tong, which is used to fix the wooden handle.

Parts of a file.

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Cutting Tools
2.1. Files
Files are classified according to the following factors:

1. The cut and spacing of teeth on file.

The teeth on a file may be of single cut or double cut. A single cut file will be having parallel teeth at 60° inclination
to the centre line and is also known as flat files. Double cut files have two times cut-teeth; one similar to those of
single cut (at 60°) and the other running diagonally across, making an angle of 80°.
The spacing between teeth is known as the pitch
to the spacing of teeth, files are classified
into the following types:
1. Rough (R) 8 teeth/cm
2. Bastard (B) 12 teeth/cm
3. Second cut (Sc) 16 teeth/cm
4. Smooth (S) 24 teeth/cm
5. Dead smooth (DS) 35 teeth/cm
6. Super smooth (SS) 50 teeth/cm

2. Shape or form of cross section of file

Different cross sections are required for shaping contour of
different forms. For example, a round hole can be
shaped only by a round file.
3. Effective length of files
The size of a file is its effective length. The distance from the point to the heal (excluding the tang) is considered
as the effective length of a file. The length of files used for heavy works varies from 200 to 450 mm, while that
for medium works varies from 150 to 250 mm. For fine works, files of length 100 to 150 mm are preferred. 7
2. Cutting Tools
2.2. Hack Saw
The hack saw blade is the most important part for the cutting process. It is specified by its length (distance between
pin holes) width, thickness and the pitch of teeth.

Hack saw

Flexible blades are made with hard teeth on a soft body, so that a slight bending cannot break
them. They are suitable to cut comparatively soft metals like mild steel or aluminium.

The sharp points of the teeth are bent alternately to sides to cut wide groove and thus provide clearance for
the blade to move. This bending of teeth to sides is called the set of the blade.

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2. Cutting Tools
2.3. Chisels
Chisels are used to cut or chip off metal from workpiece. If the metal is cut in the
cold state, the chisel used for that is called cold chisel.

https://www.youtube.com/watch?v=tOGE130sbzQ&ab_channel=MrStreetMachineDemos

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2. Cutting Tools
2.4. Scrapers
Scrapers are tools like a file or knife which have very hard cutting edges. Scraping means removal of a very thin
layer of metal similar to shaving.

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2. Cutting Tools
2.5. Drills and Reamers

Drill is a tool used to make cylindrical holes by rotating and pressing the tool against
a work piece

The parallel shank type twist drill bits are made for diameter
0.20 to 40 mm size. The taper shank type twist drills range
from 3 to 100 mm diameter.

A reamer is a tool similar to drill, which

removes a very thin layer of metal about
0.05 to 0.15 mm from the hole surface using
long cutting edges on the reamer. The
reaming process can be done by hand or by
using the drilling machine.

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2. Cutting Tools
2.6. Taps and Dies

Internal and external threads are cut on machine parts by using taps and dies respectively. They can also be used to
correct the damaged threads. For each size of thread and thread forms, a set of taps and dies is required. They are made
of hard steel similar to other tools.

Taps. Die.

The taps are inserted and rotated inside

the drilled hole by holding it in the tap Dies are used to cut external threads on
wrench round rods.
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3. Measuring and Marking Tools
3.1. Surface Plate
It is a cast iron plate having perfectly smooth and flat surface, used as a reference
surface for measuring and marking protect the surface of the plate from dust and dirt, it
is kept covered, when out of use.

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3. Measuring and Marking Tools
3.2. Try Square
The try square is used in fitting shops for scribing straight lines at right
angles to a true surface. It can also be used to test the trueness of
mutually perpendicular surfaces. It consists of a steel stock of
rectangular cross section and a steel blade fitted perpendicular to it.

3.3. Scribers
A scriber is a piece of hardened steel pointed at ends. It
is used like a pencil to mark scratch lines on the
workpiece for transfering the drawing on it.

3.4. Punches
A punch is a tool similar to a chisel, but the cutting edge
is replaced by a pointed edge. The prick punch has a
sharply pointed marking edge having included angle
approximately equal to 40°. It is used to make light
punch marks on layout lines. The centre punch has an
included angle of about 60°. They are usually used to
mark heavy punch indentation to start drilling a hole

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3. Measuring and Marking Tools

https://www.youtube.com/watch?v=V2QT2C5larE&ab_channel=UltimateHandyman

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3. Measuring and Marking Tools
3.5. Vernier Caliper
For more precise measurement of length, vernier calipers are used. There are vernier
calipers to measure length with an accuracy of 0.02 mm. A vernier caliper basically
consists of a bar having the main scale marked on it and the fixed jaw for external and
internal measurements. The adjustable vernier head having the vernier scale, is
positioned over the main scale and carries the movable jaw

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3. Measuring and Marking Tools
3.5. Vernier Caliper

https://www.youtube.com/watch?v=vkPlzmalvN4&ab_channel=WeldNotes 17
3. Measuring and Marking Tools
3.6. Micrometer
Micrometer is a precision instrument used to measure the size up to an accuracy of
0.01 mm. It consists of a semicircular frame having a cylindrical extension at its right
end and hardened anvil inside at the left end. To measure the size of a part using the
micrometer, the part is placed between the measuring face (anvil) and the spindle.
Then the spindle is advanced slowly by screwing the thimble forward. As the anvil is
about to touch the object, the further movement of it and the pressure of touching is
applied by rotating the ratchet stop. The reading on the barrel as well as thimble are
noted to get the size.

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3. Measuring and Marking Tools
3.6. Micrometer

https://www.youtube.com/watch?v=StBc56ZifMs&ab_channel=WeldNotes
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3. Measuring and Marking Tools
3.7. Vernier Hight Gauage
To measure the height of parts or to mark height accurately on an object, vernier
height gauges are used. It mainly consists of a base, a vertical main scale, a sliding
head with vernier and an auxiliary head. Usually measurement and marking are
conducted after placing the workpiece and the gauge on a surface plate. The method
of measurement is similar to that of a vernier caliper.

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3. Measuring and Marking Tools
3.8. Outside and Inside Calipers
To measure the size of or to transfer a dimension to a component, calipers are used.

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4. Tools for Assembling
4.1. Spanners
They are tools made of forged steel. The size of a spanner
is specified by the width across flats of a nut in mm or the
diameter of the bolt in inches

4.2. Pliers
Cutting pliers
Nose pliers.

4.3. Screw Drivers

4.4. Allen Keys

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5. Fitting Processes
5.1. Hack Sawings

A workpiece can be cut to the approximate size by sawing using a hack saw. The
workpiece or blank to be cut is rigidly clamped on the bench vice keeping the line of cut, a
few millimetres outside the vice jaws. The hack saw, after tightening the blade, is placed over
the cutting line of workpiece in such a way that the wooden handle in the right hand and the
other end of the frame is on the left hand. The sawing is started with a backward stroke.

The forward and backward strokes are repeated, giving more pressure during forward
movement. This makes a cut called kerf on the work. Much care should be taken during the
first few strokes for keeping the cutting without deviation from line. After forming the kerf,
the cutting can be made fast

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5. Fitting Processes
5.2. Chipping

Thick layers of metal can be removed by the process called chipping. In this process the
workpiece is fixed on the bench vice firmly and metal is removed by striking a cold chisel
on the surface of the workpiece using hand hammer.

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5. Fitting Processes
5.3. Filing

1. Cross filing: In this filing the file strokes are made in diagonal form from right to left and then from
left to right. This is the most common type of filing and is used for medium and heavy cuts.
2. Straight filing: In this filing the file is pressed and moved forward approximately right angles to the
length of the work. On back stroke the file is lifted. This type of filing is suitable to the narrow pieces
of work.
3. Draw filing: In this filing both the hands are kept on the two ends of the file blade and the blade is
kept at right angles to the length of the work. The forward and backward strokes of the file will
smoothen the surface produced by cross or straight filing.

Types of filing processes.

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5. Fitting Processes
5.3. Filing
Cross filing: In this filing the file strokes are made in diagonal form from
right to left and then from left to right as shown in Figure 3.31(a). This is
the most common type of filing and is used for medium and heavy cuts.
2. Straight filing: In this filing the file is pressed and moved forward
approximately right angles to the length of the work as shown in Figure
3.31(b). On back stroke the file is lifted. This type of filing is suitable to the
narrow pieces of work.
3. Draw filing: In this filing both the hands are kept on the two ends of the file
blade and the blade is kept at right angles to the length of the work. The
forward and backward strokes of the file will smoothen the surface produced
by cross or straight filing [Figure 3.31(c)].

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5. Fitting Processes
5.3. Filing

https://www.youtube.com/watch?
v=bssIGDwnTwA&ab_channel=KS3-5Design
%26Technology

https://www.youtube.com/watch?
v=FQY1Q9lBLy4&ab_channel=MarkCrogha
n

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5. Fitting Processes
5.4. Scraping
After filing, a small irregularity of flat surface can be corrected by pressing and rubbing the cutting edge of
the scraper. In order to identify the areas to be scraped, the smoothly finished surface is coated by a thin film
of prussian blue or red lead oil. Then a perfectly flat surface is rubbed over it gently. This will identify the
areas to the scraped.

https://www.youtube.com/watch?
v=4FS2YI3U_cc&ab_channel=093tats
u

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5. Fitting Processes
5.5 Drilling and Reaming
Drilling process
To make a hole on a workpiece, the location of
the centre of the hole is marked and a deep
punch indentation is made using a centre
punch. Then the twist drill of the required size
is fixed on the drill chuck. After completing the
machine setting, the motor is switched on.
While drilling hard metals, coolants is applied
at the cutting point to reduce the damage of the
cutting edge due to friction and heat.

Reaming

To finish a drilled hole for more smoothness as well as dimensional accuracy, reaming
is done. Reamers of required size are used for the purpose. The reaming process can
be executed by hand or with the help of a drill press.

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